Apparatus and method for applying end caps to cylindrical shells

ABSTRACT

A pair of relatively movable jaws (306) are provided with magnetic holders (306-316) for holding end caps (24) to be applied to a substantially cylindrical shell (28) positioned between the jaws; so that, closing of the jaws installs the end caps on the end edges of the shell. An end cap placing mechanism (50) removes end caps from a source (356) by means of a pair of rotatably mounted gripper arms (364) which place the caps in the magnetic holders.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to the following concurrently filedapplications of: (1) James C. Foote, Jr., Robert F. Allen, Paul E.Bailey, Dean B. Campbell, Thomas A. Cipolla, William G. Hoyt, Robert L.Huseby, Lyndon R. Huttemann, David H. Lancy, William C. Lebbon, StephenM. Reinke, Thomas E. Stark and Joseph A. Watkins for Apparatus andMethod for Forming and Loading a Magazine for Prewound Spools of WebMaterial; and (2) Stephen M. Reinke, James C. Foote, Jr., Thomas A.Cipolla, William G. Hoyt, Lyndon R. Huttemann and Joseph A. Watkins forApparatus and Method for Removing a Very Open Shell from a FormingMandrel.

DESCRIPTION Technical Field

The present invention relates to apparatus and methods for applying endcaps to cylindrical shells. More particularly, the invention concernssuch apparatus and methods in which substantially cylindrical metalshells are fitted with disk like end caps having peripherally andaxially extending flanges which telescopically receive the end edges ofthe shell.

Background Art

Numerous techniques have been developed over the years for installing aclosure or the like on a shell or container. For example, U.S. Pat. No.1,310,118 discloses an apparatus for applying metal rings to the lip ofa container in which axial movement of a plunger initially seats thering on the lip and then causes a plurality of arms to move radiallyoutwardly to press the ring against the container. U.S. Pat. No.2,940,232 discloses an apparatus for use with photographic film in whichstrips of film are wound on spools, after which the wound spools areinserted axially into previously formed cylindrical magazine shells towhich one end cap has already been applied, the shells having axiallyextending lips through which the leader of the film strip extends in thefamiliar manner. The cap for the open end of the shell is later applied.U.S. Pat. No. 3,668,824 shows a device for securing a valve in the neckof an aerosol container in which radially moving arms press the valveinto engagement with the sides of the lip of the container. Commonlyassigned U.S. Pat. No. 3,724,162 discloses a mechanism for applying endcaps to magazines used for photographic film, in which the caps arepicked up by a plurality of radially movable shoes which carry the capinto position on the end edges of the cylindrical magazine shell andthen are moved outwardly to stake the cap in place. U.S. Pat. No.3,961,463 discloses a self releasing capper chuck in which radiallymovable jaws grip a closure on an inside diameter, move the closure intoengagement with a container and then retract to leave the closure inplace on the container.

While cap applying apparatus and methods of the types shown in thesepatents have received a certain commercial acceptance, a need hasexisted for an apparatus which could accurately apply end caps to bothends of a cylindrical shell and then hold the caps in place while theapparatus moves the assembly of shell and caps to a separate locationfor staking.

SUMMARY OF THE INVENTION

An objective of the invention is to provide an improved apparatus andmethod for applying end caps to a cylindrical shell in which a very openshell is received, transferred to a location for lateral installation ofa prewound spool, closed about the spool to form a cylindrical shell andprovided with end caps.

Another objective of the invention is to provide such an improvedapparatus and method which can orient such a very open shell forinstallation of a prewound spool.

Still another objective of this invention is to provide such anapparatus and method which can position such a very open shell forclosing about a prewound spool.

Yet another objective of this invention is to provide such an apparatusand method which can provide repeatable, controlled end cap to end capdimensions for the completed magazine.

These objectives are given only by way of illustrative examples; thus,other desirable objectives and advantages inherently achieved by thedisclosed apparatus and method of the invention may occur or becomeapparent to those skilled in the art. Nonetheless, the scope of theinvention is to be limited only by the appended claims.

The means for applying end caps preferably comprises at least one pairof relatively movable jaws mounted on an assembly dial, the jaws beingpositioned one opposite each end of a very open shell which is heldwithin the jaws of a shell removal mechanism. In the illustratedembodiment, eight pairs of such jaws are arranged around the assemblydial for receiving very open shells in sequence from a first dial wherethe shells are formed from blanks. Means are located on each jaw forholding one end cap, such as recess in an anvil made of magneticmaterial. Adjacent the assembly dial is provided a mechanism for placingend caps in each of the means for holding. A means for closing the jawsto apply the end caps is provided. Preferably, the movable jaws areconstrained to parallel movement toward and away from each other toensure that the end caps are properly installed. A rotatable crank shaftis provided between the jaws and is connected to the jaws by oppositelymovable connecting rods; so that, rotation of the crank shaft causes thejaws to open and close.

End caps are placed within the jaws of the means for applying them by amechanism which comprises a pair of cap delivery wheels rotatablymounted next to the assembly dial, each delivery wheel comprising aplurality of circumferentially spaced pockets for receiving end caps,means for feeding end caps into the pockets, and a frame mounted forrotation adjacent to the second dial. A pair of cap transfer arms arepivotably mounted to the frame, each arm having an outer end selectivelypositionable upon rotation of the frame into proximity either with oneof the peripheral pockets or with one of the means for holding end capsin the means for applying end caps. Means are provided for selectivelypivoting the cap transfer arms relative to the frame, toward or awayfrom the peripheral pockets or toward or away from the means forholding.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objectives, features and advantages of theinvention will be apparent from the following more particulardescription of the preferred embodiments of the invention, asillustrated in the accompanying drawings.

FIG. 1 shows an exploded perspective view of a known type of magazinefor photographic film, illustrating one prior art technique forinserting a prewound spool axially into the shell of the magazine andapplying the end caps.

FIG. 2 shows an exploded perspective view of a known type of magazinefor photographic film, illustrating a method for inserting a prewoundspool radially, laterally into the shell of the magazine and applyingthe end caps.

FIG. 3 shows a simplified schematic front elevation view of asynchronous film spooling and packaging apparatus embodying theapparatus according to the invention.

FIG. 4 shows a schematic, partially fragmentary front elevation view ofthe mechanisms which remove a very open shell from the mandrel anddeliver it to an assembly station where a prewound spool is insertedinto the shell.

FIG. 5 shows an enlarged sectional view taken along line 5--5 of FIG. 4.

FIG. 6 shows the stationary cam plate which actuates the means forremoving a very open shell.

FIG. 7 shows a front elevation view of the means for removing a veryopen shell.

FIG. 8 shows a side elevation view of the mechanism of FIG. 7.

FIG. 9 shows a view of the cam follower arm of the mechanism of FIG. 8,taken along line 9--9 in FIG. 8.

FIG. 10 shows an exploded perspective view of the nest mechanism whichreceives and holds the very open shells.

FIG. 11 shows a side elevation view of the mechanism according to theinvention for applying end caps to the magazine and holding the caps onthe magazine during transport to the staking mechanism.

FIG. 12 shows a sectional view taken along line 12--12 of FIG. 11.

FIG. 13 shows a sectional view taken along line 13--13 of FIG. 12.

FIG. 14 shows a top view of the mechanism of FIG. 11.

FIG. 15 shows a sectional view taken along line 15--15 of FIG. 14.

FIG. 16 shows a sectional view taken along lines 16--16 of FIG. 14.

FIG. 17 sows a sectional view taken along line 17--17 of FIG. 11.

FIG. 18 shows a fragmentary view taken along line 18--18 of FIG. 11.

FIG. 19 shows a fragmentary front elevation view of the mechanism forsupplying end caps to the mechanism of FIG. 11.

FIG. 20 shows a side elevation view, partially in section, of themechanism of FIG. 19.

FIG. 21 shows an enlarged fragmentary view of the mechanism of FIG. 20,illustrating how the end caps are retained by the star wheels.

FIG. 22 shows a front elevation view, partially in section, of themechanism for transferring a prewound spool into a preformed shell.

FIG. 23 shows a top plan view of the mechanism of FIG. 22.

FIG. 24 shows a side elevation view, partially in section, of themechanism of FIG. 22.

FIG. 25 shows a section view taken along line 25--25 of FIG. 24.

FIG. 26 shows a plan view of the cam plate used in the mechanism of FIG.22.

FIG. 27 shows a side elevation view, partially fragmentary and partiallyin section, of the station of the apparatus of FIG. 3 at which prewoundspools are inserted radially, laterally into the very open shells, afterwhich skewers are inserted, the very open shell is closed and the endcaps are installed.

FIG. 28 shows a front elevation view of the mechanism of FIG. 27.

FIG. 29 shows a top view, partially in section, of the actuatormechanism for the mechanism of FIG. 27.

FIG. 30 shows a view taken along line 30--30 of FIG. 29.

FIG. 31 shows a sectional view taken along line 31--31 of FIG. 30.

FIG. 32 shows a front elevation view of the mechanism for closing a veryopen shell about a prewound spool, in its retracted position.

FIG. 33 shows the mechanism of FIG. 32 in its extended, open position.

FIG. 34 shows the mechanism of FIG. 32 in its extended, closed position.

FIG. 35 shows a side elevation view, partially in section, of themechanism of FIG. 32.

FIG. 36 shows an enlarged elevation view of the shell closing mechanism.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following is a detailed description of the preferred embodiments ofthe invention, reference being made to the drawings in which the samereference numerals identify the same elements of structure in each ofthe several Figures.

FIG. 1 illustrates a known process for loading photographic filmmagazines. A spool 10 has been used which comprises a central core, notillustrated, on which is wound a strip 12 of photographic film. Spool 10includes a pair of end flanges 14 from which extend hollow axial hubs16. A preformed metal shell 18 has been used which comprises a pair ofaxially extending lips 20c, 20t between which strip 12 is withdrawn fromor wound back into the magazine in use by the consumer. These axiallyextending lips typically are different in geometry, lip 20c being foldedor crimped back on itself and lip 20t being essentially tangent to thecylindrical preformed shell 18. Typically, preformed shell 18 has beenformed from a substantially flat rectangular blank, not illustrated, inwhich lips 20c, 20t have previously been formed. To prevent leakage oflight into the magazine, lips 20c and 20t have for many years beencovered with a lightlock material 22 such as black velvet or plush whichfirmly but gently engages the surfaces of the film and prevents lightleakage into the magazine. The ends of the magazine are closed by a pairof annular end caps 24, each having an aperture 26 for rotatablyreceiving hubs 16 and a circumferentially extending groove and flangefor fixedly engaging the end edges of preformed shell 18. Such magazineshave been assembled by inserting the prewound spool of film axially intopreformed shell 18 and then applying and staking end caps 24. While thisspooling and assembling process is reliable and has been rather widelyused, the apparatus for practicing the process tends to be limited inspeed.

FIG. 2 illustrates how a magazine can be assembled using, in part, themethod and apparatus of the present invention. In this instance, insteadof the essentially cylindrical preformed shell 18 used in the past topermit axial insertion of the prewound spool, a very open preformedmetal shell 28 is provided. Very open shell 28 is configured such thataxially extending lips 20c, 20t are spaced far enough apart to permitthe prewound spool to be inserted laterally or radially into shell 28.Then, very open shell 28 is closed about the prewound spool to asubstantially cylindrical configuration 30 with the lead end of strip 12captured between lips 20c, 20t. Then end caps 26 are applied and stakedto complete the magazine. In the remainder of this specification, theprocess and apparatus will be described for forming the very open shell28, inserting a prewound spool therein, closing the shell and applyingthe end caps.

OVERALL OPERATION

FIG. 3 illustrates the overall layout of a film spooling and packagingapparatus embodying the apparatus according to the invention. A rigid,vertically standing face plate 32 is preferred to provide a mount forthe components of the invention; however, face plate 32 may be orienteddifferently or replaced with a structural framework without departingfrom the scope of the invention. A shell blank feeding mechanism 34receives substantially flat, rectangular metal blanks to be formed intothe cylindrical side wall of the completed magazine, each blank havingbeen previously provided with lips 20c, 20t and lightlock strips 22. Theshell blanks are fed one at a time to sequentially presented formingmandrels mounted on mandrel carriers 36 which in turn are mounted on afirst forming dial 38 which rotates intermittently to index mandrelcarriers 36 from position to position. As forming dial 38 is indexed,each mandrel carrier 36, having received a shell blank from feedingmechanism 34, is presented to a forming station 40 where very open shell28 is formed about the mandrel. As forming dial 38 is indexed again,each mandrel carrier, with very open shell 28 formed about its mandrel,is presented to a shell removal station 42 where very open shell 28 isremoved from the mandrel by a shell removal mechanism 44, FIGS. 28 to31, mounted on an adjacent assembly dial 46.

As assembly dial 46 is indexed away from removal station 42, removalmechanism 44 is rotated by a cam and follower to position very open formshell 28 between the movable jaws of one of a plurality of end capapplying mechanisms 48 according to the present invention, which arealso mounted on dial 46. Then when dial 46 has stopped, an end capplacing mechanism 50 according to the present invention transfers a pairof end caps to magnetic holders on the anvils of end cap applyingmechanism 48 between which very open shell 28 has been positioned.Assembly dial 46 continues to index until a magazine assembly station 52is reached, where a prewound spool will be inserted.

While the overall operations described in the preceding paragraphs aretaking place, empty spools are provided to a spool winding station 54,which is described in copending, commonly assigned application Ser. No.595,130. Once a spool has been wound, it is picked up and swung up intothe waiting very open shell 28 at assembly station 52, by a wound spooltransfer mechanism 56. To hold the spool steady during subsequentoperations, a pair of skewers, not visible in FIG. 3 but shown in FIG.27, are then inserted through openings in the jaws of end cap applyingmechanism 48 and apertures 26 of end caps 24, into the hollow hubs 16 onthe spool. A shell closing mechanism 58, shown only fragmentarily inFIG. 3 but in detail in FIGS. 32 to 36, is then extended to surroundvery open shell 28 and close it about the prewound spool. Wound spooltransfer mechanism 56 is then withdrawn and end cap applying mechanism48 is actuated to close its jaws and apply end caps 24 to the nowcylindrical end edges of the shell. Shell closing mechanism 58 and thepair of skewers are then withdrawn to permit assembly dial 46 to indexto end cap staking station 60 where end caps 24 are staked into firmengagement with the cylindrical walls of the completed magazine.Assembly dial 46 then indexes to a magazine removal station 62 where thejaws of end cap applying mechanism 48 are opened and the completedmagazine is removed by a magazine removal mechanism 64.

ASSEMBLY DIAL 46

Shell removal mechanism 44 is supported by adjacent assembly dial 46,illustrated schematically in FIG. 4, which comprises an annular platemounted for rotation relative to face plate 32 by a conventionalindexer, not illustrated. Around the periphery of assembly dial 46 isarranged a plurality of end cap applying mechanisms 48 and on one sideof each mechanism 48 is mounted a shell removal mechanism 44, some ofwhich are shown in solid lines in FIG. 4, some in phantom lines. Themanner of mounting assembly dial 46 to face plate 32 is illustrated inFIG. 5. An opening is provided through face plate 32, through which acentral, stationary support tube 68 extends from a stationary support,not illustrated, at the back side of face plate 32. At its outer end,support tube 68 comprises a bearing mounting surface 70 for the innerrace of a bearing 72. The outer race of bearing 72 is supported within acentral counter bore 74 provided in an annular dial support plate 76 onthe outer side of which assembly dial 46 is rigidly attached by bolts,for example. At its inner side, support plate 76 is rigidly attached toan annular adapter plate 78 having a central bore through which supporttube 68 extends. Adapter plate 78 also supports the outer race ofbearing 72. Adapter plate 78 is operatively attached to a conventionalindexer, not illustrated, for rotating dial 46. An actuator shaft 80extends through support tube 68 to a mechanism for actuating anddeactuating end cap applying mechanisms 48, as will be discussedsubsequently.

As shown in FIGS. 5 and 6, behind assembly dial 46 and rigidly attachedto face plate 32 is an essentially annular cam plate 82 which cooperateswith a cam follower on shell removal mechanism 44 to swing very openshell 28 away from shell removal station 42 and place the shell inposition for cooperation with one of end cap applying mechanisms 48. Asseen in FIG. 6, cam plate 82 comprises a dwell segment 84 extending overapproximately five eighths of the circumference of the plate and adecreasing radius segment 86 extending over the remainder of thecircumference. As assembly dial 46 is rotated, the cam follower of eachshell removal mechanism 44 rolls from the outside edge of dwell segment84 into a slot 88 in decreasing radius segment 86, just as theassociated end cap applying mechanism 48 is rotated away from magazineremoval station 62. Subsequently, each cam follower is shifted fromsegment 86 back to segment 84, one indexing step after the associatedend cap applying mechanism 48 is rotated away from shell removal station42. This shifting of each cam follower is accomplished by means of aradially movable switch plate 90 having a slot segment 92 which can bepositioned to receive a cam follower from slot 88 or to deliver the camfollower to the outside edge of dwell segment 84. Switch plate 90 may bemoved when necessary by a crank arm 94 pivotably mounted at one end toface plate 32 and pivotably connected at its other end to a link 96which in turn is pivotably connected to the radially outer end of switchplate 90. Crank arm 94 may be driven by a conventional oscillator, notillustrated.

Shell removal mechanism 44 is illustrated in FIGS. 7 to 10. A mountingplate 98 is attached to one side of each end cap applying mechanism 48as illustrated fragmentarily in FIG. 7 and supports a transfer armhousing 100 having a rearwardly projecting shaft housing 102. Mountedfor rotation within housing 102 is a shaft 104 which extends rearwardlytoward face plate 32 through a bore 106 in dial 46. At its rearmost end,shaft 104 fixedly supports a cam follower 108 comprising a clamp block110 fixedly attached to the end of shaft 104, a pair of flexure elements112 extending from block 110 essentially parallel to cam plate 82, aroller support block 114 attached to the opposite ends of flexureelements 112 and a roller 116 rotatably supported by block 114. Asassembly dial 46 is rotated, roller 116 rolls along the periphery ofdwell segment 84 of cam plate 82 or through slot 88 in decreasing radiussegment 86. As roller 116 traverses dwell segment 84, shaft 104 remainsstationary; however, as roller 116 moves through slot 88, shaft 104 isrotated to position shell removal mechanism 44 to acquire a very openshell 28 from the forming mandrel, as indicated schematically at theright side of FIG. 6, and then to transfer the shell into position forcooperation with the associated end cap applying mechanism 48.

At the opposite end of shaft 104 is fixedly mounted a pulley 118 aboutwhich a timing belt 120 is wrapped. A pulley 122 is supported on a shaft124 rotatably supported between an arm 126 extending from housing 100essentially parallel to assembly dial 46 and a support plate 128attached to arm 126. Timing belt 120 also is wrapped around pulley 122.The tension of timing belt 120 may be adjusted in the familiar mannerusing a tension roller 130 slidably mounted on the side of housing 100.To the rear of arm 126 is provided a second arm 132 extending fromhousing 100 essentially parallel to dial 46. A front support plate 134is fixedly mounted for rotation with shaft 124. A rear support plate 136is fixedly mounted on a shaft 138 rotatably mounted near the end ofsecond arm 132 and coaxial with shaft 124. As seen in FIGS. 7, 8, and10, support plates 134, 136 extend away from shafts 124, 138 and areattached at their outer ends to an elongated support base 140 for a pairof fixed claws 142, 144 of shell removal mechanism 44. Base 140 includesan outwardly protruding tongue portion 146 having a pair of laterallyprotruding stub axles 148, 150 in its side edges, axles 148, 150 beingloosely received in pentagonal shaped apertures 152, 154 provided nearreference edges 156, 158 of claws 142, 144. The vee-shaped sides ofapertures 152, 154 normally support axles 148, 150, with clearances tothe remaining sides of the apertures which serve as stops against excessmovement. A tie plate 160 extends between claws 142, 144 and fixes theclaws in parallel planes by means of through pins 162, 164 which matewith corresponding apertures in the claws. A pair of bearing buttons166, 168 are attached to the inner sides of claws 142, 144 facing tongueportion 146 and are provided at their rounded tips with a smallclearance to tongue portion 146. Tie plate 160 is biased toward tongueportion 146 by means of a leaf spring 170 attached by a hold down plate172 to support base 140. The outer end of spring 170 extends into apocket 174 in tie plate 160. The movement of tie plate 160 toward tongueportion 146 is limited by a bearing button 176 centrally located nearthe outer end of tongue portion 146.

Because of the loose fit between stub axles 148, 150 and apertures 152,154, the assembly of tie plate 160 and claws 142, 144 is permittedlimited universal movement relative to support base 140. In thedirection transverse to support plates 134, 136, this movement islimited by bearing buttons 166, 168 and the sides of apertures 152, 154.In the direction about stub axles 148, 150, this movement is limited bybearing button 176 and the sides of apertures 152, 154 if the assemblyis rotated toward tongue portion 146; whereas, if the assembly isrotated away from tongue portion 146, this movement is limitedultimately by contact between claws 142, 144 and support plates 134,136. This range of movement is important to proper operation of theapparatus according to the invention. When shell removal mechanism 44 isswung into the position shown in FIG. 7, reference edges 156, 158 mustengage properly with positioning bars 178, 180 on a reference datumplate 182 mounted between the jaws of end cap applying mechanism 48. Therange of movement of the assembly of claws 142, 144 and tie plate 160ensures that the assembly will be able to orient properly against thepositioning bars to ensure that very open shell 28 is properlypositioned to receive a prewound roll of film, to be closed about thefilm and to receive a pair of end caps.

Each claw 142,144 comprises a central opening 184 sized to permit axialpassage of the forming mandrel, not illustrated, with a shell clamped inplace. Opening 184 is also sized to permit the shell to spring into andbe firmly held within the central opening due to the spring force of theshell. Since the spring force of the shell causes it to spring into afixed configuration within opening 184, changes in the materialproperties of the shell can be accommodated without influencing theshape of the shell as held within opening 184. Each claw includes athroat 186 on one side of opening 184, the throat being sufficientlywide to permit lateral passage of a prewound roll of film into a veryopen shell 28 held between the two claws. Each claw includes on the sideof throat 186 closer to support base 140 a tine 188 which engages theshell near lip 20t. Spaced along the circumference of opening 184 fromtine 188, each claw includes a shell positioning protrusion 190 whichprevents the shell from springing open farther than necessary. On theopposite side of throat 186 from tine 188, claw 142 includes a tine 192which engages the roll formed shell in the crimp formed by lip 20c. Inthe case of claw 144, a different arrangement is preferred on theopposite side of throat 186. The forming mandrel for the very openshell, not illustrated, is moved outwardly from forming dial 38 to aposition where the shell can be removed by mechanism 44. A pair ofclamping fingers, not illustrated, press against the roll formed shellnear lip 20t and move easily past tines 188 as the mandrel and the rollformed shell are moved outwardly. In contrast to this, a clamp member,not illustrated, which is engaged in the crimp formed by lip 20c, wouldprevent the mandrel and shell from passing a tine configured like tine192 of claw 142, if such tine were used on claw 144. So, claw 144 isprovided with a tine 194 spaced circumferentially away from the path ofthe clamp member. To ensure that the end of the shell held by claw 144is positioned identically with that held by claw 142, an additionalshell positioning protrusion 196 is provided on claw 144 between tine194 and protrusion 190.

END CAP APPLYING MECHANISM 48

FIGS. 11 to 18 illustrate the structure of the end cap applyingmechanism 48 according to the present invention. A pair of frame members198,200, which are essentially mirror images of each other, areprovided. Each frame member comprises a base flange 202 for rigidattachment to dial 46, an outwardly protruding leg 204 formed integrallywith flange 202 and a radially extending arm 206 formed integrally withleg 204. As shown in FIG. 17, legs 204 are joined near base flanges 202by a cross member 208. As shown in FIG. 12, the radially outer ends ofarms 206 are joined by a bearing block 210 which comprises a centralbore 212 for receiving a bearing 214 which supports one end of a crankshaft 216 extending lengthwise of mechanism 48. Near its other end,crank shaft 216 is supported by a two piece bearing block 218a,218b, thetwo pieces being attached respectively to frame members 198,200. Bearingblock 218a,218b is assembled around crank shaft 216 by a pair of bolts220, one passing on either side of crank shaft 216 and only one beingshown in phantom in FIG. 12. Crank shaft 216 comprises two pairs ofthrows 220a,220b located adjacent to bearing block 210, and 222a,222blocated on the opposite side of bearing block 218 from pair 220a,220b.The throws in each pair are positioned 180 degrees apart about the axisof crank shaft 216; so that, connecting rods riding on the throws ofeach pair will be moved in opposite directions as crank shaft 216 isrotated.

Approximately midway between bearing blocks 210,218, a detent ring 224is rigidly connected between frame members 198,200 and around crankshaft 216 as shown in FIGS. 12, 13, and 14. A central bore 226 isprovided in detent ring 224, the bore having a detent recess 228 on adiameter midway between frame members 198,200. On either side of detentring 224, crank shaft 216 is provided with radially extending, integralflanges 230,232. Each flange includes diametrally oppositely inwardlyextending slots 234 which are joined at their inner ends by a diametralbore 236 which houses a spring 238. Slidably mounted in each of slots234 is a roller guide block 240, the pair of guide blocks mounted onopposite sides of diametral bore 236 being biased outwardly in slots 234by spring 238. Between the guide blocks on flange 230 and those onflange 232 are mounted rollers 242 which are biased into contact withthe surface of bore 226 in detent ring 224. Thus, for each 180 degreesof rotation of crank shaft 216, one of rollers 242 enters detent recess228 to deter further rotation of crank shaft 216.

Rotation of crank shaft 216 actuates end cap applying mechanism 48. Apair of essentially identical, rugged platens 244,246 is positioned oneon each side of crank shaft 216 between frame members 198,200.Preferably, platens 244,246 are ductile iron castings. In use ofmechanism 48, platens 244,246 are moved toward each other to apply endcaps and away from each other to release a completed magazine. Toconstrain platens 244,246 to essentially parallel movement, guides areprovided at both of bearing blocks 210,218. As best seen in FIGS. 12 and14, bearing block 210 includes spaced, radially extending protrusions248 which support a pair of guide posts 250,252 extending essentiallyperpendicular to the surface of dial 46. Each of platens 244,246comprises a radially outwardly opening yoke having a pair of side arms254,256. As seen in FIGS. 11 and 17, attached to the side of each arm254 which faces arm 256 on the opposite platen is a guide support block258 secured by oppositely extending bolts 260 and 262. As seen in FIG.17, support block 258 includes an elongated guide surface 264 which maybe covered with a suitable self lubricating material such as Oilite,Teflon or Delrin and which bears against a flat side of one of guideposts 250,252. Guide posts 250,252 are provided with intermediatelylocated elongated slots 266. A spacer block 268 is captured in each slotby a back block 270 held by bolts extending from support block 258. Thesurface of back block 270 contacting guide posts 250,252 is covered witha suitable self lubricating material. Thus, as platens 244,246 move upand down as viewed in FIG. 17, their motion is guided by surfaces 264and blocks 270 as they slide along fixed guide posts 250,252. Thus,guide posts 250,252 restrain both radial and tangential movementrelative to assembly dial 46.

Guidance against tangential movement relative to assembly dial 46 isprovided at bearing block 218 as best seen in FIGS. 12 and 14. A pair ofrectangular crossection guide posts 272,274 are attached to oppositesides of bearing block 218 by means of bolts passing on either side ofcrank shaft 216. Guide posts 272,274 extend parallel to guide posts250,252 and pass outwardly from bearing block 218 through openings 276in platens 244,246. Attached to the inner side of each of platens244,246 and extended across opening 276 is a bearing block 278 havingflat side surfaces which slidably engage the flat side surfaces each ofguide posts 272,274. Thus, as platens 244,246 move up and down as viewedin FIG. 11, their motion is guided by fixed guide posts 272,274.

Platens 244,246 are operatively connected to crank shaft 216 by pairs ofconnecting rods mounted on crank throws 220a,220b and 222a,222b. Tosimplify illustration, only one pair of connecting rods 280,282 is shownin FIG. 11, the pair mounted on crank throws 221a,222b. Connecting rod280 extends outwardly into an opening 284 in platen 246 where it isrotatably connected to a wrist pin 286 extending across opening 284. Asimilar arrangement, not illustrated, operatively connects connectingrod 282 to platen 244. At crank throws 220a,220b, a further pair ofconnecting rods, not illustrated, is mounted between the crank throwsand wrist pins 288 extending across hollows 290 in the inner side ofeach platen, as seen in FIGS. 11, 14, and 16. Thus, as crank shaft 216is rotated, platens 244,246 move toward each other during an initial 180degrees of rotation, at which time one of rollers 242 engages detentrecess 228; and then away from each other during the next 180 degrees ofrotation, at which time the other of rollers 242 engages detent recess228. To more securely hold the platens in their closest positionfollowing application of end caps to a magazine as will be describedsubsequently, each of platens 244,246 is provided on its outer surfacewith a cantilevered leaf spring 292 which extends over the space betweenside arms 254,256 of the platen yoke. When the platens are brought totheir closest position, each spring 292 bears resiliently against anoutward extension 294 of bearing block 210, thereby biasing the platenstoward their open position and taking up any back lash in the crankmechanisms. This maintains a consistent dimension between the end capapplying anvils discussed in the next paragraph and gives repeatable,accurate end cap to end cap dimensions on the completed magazine.

Actual application of end caps is accomplished by a pair of juxtaposedtools 296,298 mounted on the inner sides of side arms 254,256. Each tool296,298 comprises a face plate 300 supported on the inner sides of sidearms 254,256 and extended across the opening of the platen yoke. Asshown in FIG. 15, a bore 302 is provided through face plate 300, withinwhich a plastic bushing 304 is seated. Mounted within bushing 304 is anend cap applying anvil 306 which is made from a magnetic material. Asshown in FIGS. 14 and 15, anvil 306 comprises a central portion 308having an outwardly opening concavity 310 surrounding a central bore312. Concavity 310 and central bore 312 provide access to a loadedmagazine held between anvils 306, as will be described in more detailsubsequently and also facilitate detection of missing or misaligned endcaps using optical mean, for example, not illustrated. At its inner end,central bore 312 is provided with a counter bore 314 for receiving endcaps 24 in a manner to be described subsequently. At its outer end,central bore 312 is provided with a plurality of peripheral notches 316which provide alternate magnetic pole locations for magnetic retentionof the end caps and also cooperate with a finished magazine ejector atmagazine removal station 62. Magnetization of anvils 306 to provide suchalternate poles can be achieved using conventional techniques, such asthose described in the Permanent Magnet Design and Application Handbook,Robert E. Krieger Publication Company, Malabar, Fla. 1986. Anvil 306further comprises laterally extending portions 318,320 which rest on theouter surface of base plate 300. Normally, anvils 306 follow base plates300 during application of an end cap unless there is an exceptionalsituation, such as a cocked magazine. They then will move relative tobase plates 300 to relieve the problem and prevent damage. The anvilsclose only to a fixed spacing, rather than until the end caps bottom outon the closed shell, which helps to control dimensions of the completedmagazine. During such execeptional situations, portions 318,320 tend torise slightly above the surface of base plate 300 as anvil 306 movesslightly through bushing 304. The force applied to anvil 306 iscontrolled by a pair of cantilevered leaf spring assemblies 322,324which are attached by suitable bolts 326 to the platens just outside theyoke of the platen adjacent to side arms 254,256. The free ends ofspring assemblies 322,324 are provided on their inner sides with plasticcontact buttons 328 which bear on the ends of laterally extendingportions 318,320, thereby resisting movement of anvils 306 throughbushing 304.

FIG. 18 shows a view along line 18--18 of FIG. 11, in which a referencedatum plate 182 is shown attached to the radially outer faces of guideposts 250,252. Datum plate 182 extends toward the side of end capapplying mechanism 48 which supports shell removal mechanism 44, aspreviously described. Mounted on datum plate 182 are a pair of laterallyspaced positioning bars 178,180 which cooperate with reference edges156,158 of fixed claws 142,144 of the shell removal mechanism. Thus,when the shell removal mechanism 44 is swung between anvils 306, itcomes to rest with edges 156,158 contacting positioning bars 178,180 andvery open shell 28 positioned opposite central bores 312, as indicatedschematically in FIG. 4.

END CAP PLACING MECHANISM 50

FIGS. 19, 20 and 21 illustrate details of end cap placing mechanism 50.A standoff housing 330 is attached to face plate 32 above assembly dial46 and rotatably supports a shaft 332 on a pair of bearings 334. Shaft332 may be driven by a conventional indexer, not illustrated. At itsouter end, shaft 332 is provided with a hub 336 to which is attached afirst annular star wheel 338 having spaced around its circumference aplurality of semicircular recesses 340 for receiving end caps 24. Anannular spacer 342 is attached at its inner end to first star wheel 338and at its outer end to a second star wheel 344 also having a pluralityof recesses 340 axially aligned with those of star wheel 338.Surrounding the assembly of hub 336, star wheels 338,344 and annularspacer 342, is a housing comprising a back guide ring 346 mounted on theouter end of stand off housing 330, an outside annular spacer 348attached at its inner end to guide ring 346 and at its outer end to afront guide ring 350. As shown in FIG. 21, outer guide ring 350 extendsradially inwardly past the circumference of star wheel 344; so that, endcaps 24 carried in recesses 340 are prevented from falling out. Backguide ring 346 is similarly sized for recesses 340 in star wheel 338. Tokeep end caps 24 from falling in the opposite directions, outsideannular spacer 348 is provided with circumferentially and radiallyextending flanges 352,354 which extend radially inwardly past thecircumference of the adjacent star wheels. End caps 24 are fed intorecesses 340 from a pair of chutes 356, one of which is visible in FIG.19, which extend through outside annular spacer 348 and gravity feed theend caps into recesses 340 as star wheels 338,344 are rotated by shaft332.

As star wheels 338,344 rotate clockwise as seen in FIG. 19, end caps 24carried in recesses 340 eventually reach the lowermost point 358 in therotation of the star wheels, where they are removed from the star wheelsfor placement in end cap applying mechanism 48. On either side of point358, guide rings 346,350 are provided with a plurality ofcircumferentially spaced permanent magnets 360 which hold the end capsagainst the guide rings at this location, to prevent their dropping outthrough arcuate radial slots 362 provided through annular spacer 348.Slots 362 and corresponding gaps in flanges 352,354, not illustrated,provide access to end caps 24 by a pair of vacuum gripper arms 364rotatably supported by face plate 32 adjacent to the assembly of starwheels. A frame 366 is mounted for rotation in front of face plate 32and comprises a back plate 368 rigidly attached to an outwardlyprojecting base plate 370. Back plate 368 is connected through anopening in face plate 32 to a conventional oscillator 371 mounted on theopposite side of face plate 32. Each vacuum gripper arm 364 is pivotablyattached by a pin 372, only one of which is visible in FIG. 20, to anactuator arm 374 which in turn is pivotably attached to base plate 370at pin 376. To provide a limited range of rotation of actuator arm 374relative to back plate 368, side guides 378 are provided. To provide alimited range of movement of vacuum gripper arm 364 relative to actuatorarm 376, a breakaway pin 380 is provided which extends through a bore invacuum gripper arm 364 above pin 372 and a bore provided in a bearingblock 382 attached to the upper end of actuator arm 374. A spring 384 iscaptured between a head 386 on breakaway pin 380 and bearing block 382and the opposite end of pin 380 is secured with a clamping collar 388.Pivoting movement of actuator arms 374 is limited by side guides 378supported between the arms on a leg 390 attached to base plate 370.

The two assemblies of actuator arm 374 and vacuum gripper arm 364 arepivoted by means of a double eccentric mechanism 392 supported on thefront face of back plate 368. A crank arm 394 is pivotably mountedbetween a pair of brackets 396, only one of which is visible in FIG. 20,by means of a shaft 398. The opposite ends of shaft 398 are providedwith eccentric throws 400, only one of which is visible in FIG. 20, thethrows being 180 degrees out of phase with each other. One throw isjoined by a connecting rod 402, partially obscured in FIG. 20, to pin372 of the nearer or right hand actuator arm 374; while the other throwis joined by a connecting rod 404, shown fragmentarily in FIG. 20, topin 372 of the farther or left hand actuator arm 374. Thus, pins 372perform the dual functions of pivotably connecting vacuum gripper arms364 to actuator arms 374 and of pivotably connecting rods 402,404 to therespective assemblies of vacuum gripper arm and actuator arm. Crank arm394 is oscillated by an actuator rod 406 pivotably attached to the outerend of crank arm 394 and extended rearwardly through face plate 32 to aconventional oscillator, not illustrated. To permit actuator rod 406 towithstand the rotation of frame 366, a swivel bearing 408 is provided onthe end of rod 406 remote from crank arm 394.

In operation of end cap placing mechanism 50, end caps 24 are fed intorecesses 340 of star wheels 338,344 as the assembly of star wheels isstepped along in rotation. As end cap applying mechanism 48 is rotatedby assembly dial 46 into position to receive a pair of end caps, indexer371 is actuated to rotate vacuum gripper arms 364 into the positionsshown in FIG. 20, with the tips of the vacuum gripper arms spaced fromthe end caps in recesses 340, as shown for the right hand vacuum gripperarm in FIG. 20. Actuator rod 406 is then pulled toward the back of faceplate 32, so that double eccentric mechanism 392 causes connecting rod404 to move to the left and connecting rod 402 to move to the right, asillustrated in FIG. 20. Such movement of the connecting rods causes thetips of the vacuum gripper arms to move apart from each other intocontact with end caps 24 in recesses 340, as shown for the left handvacuum gripper arm in FIG. 20. In practice, the vacuum gripper arms arecaused to overtravel slightly as they are moved apart, to ensure thatend caps 24 are properly acquired from star wheels 338,344 and, as willbe subsequently discussed, deposited within anvils 306. Vacuum is thenapplied to the gripper arms to pull end caps 24 away from magnets 360.Actuator rod 406 is then pushed toward the front of face plate 32, sothat double eccentric mechanism 392 causes the tips of the vacuumgripper arms to move toward each other away from recesses 340 whilecarrying a pair of end caps 24. Oscillating drive 371 is then actuatedto rotate vacuum gripper arms 364 downward into position betweenmagnetic anvils 306 of end cap applying mechanism 48. Actuator rod 406is then pulled toward the back of face plate 32, so that doubleeccentric mechanism 392 causes the tips of the vacuum gripper arms tomove apart from each other and place end caps 24 within counterbores 314of anvils 306, at which time the vacuum is released to leave the endcaps magnetically held by the anvils. The overtravel of the vacuumgripper arms, previously discussed, ensures that end caps are properlydeposited within the anvils. Actuator rod 406 is then pushed back towardthe front of face plate 32, so that the tips of the vacuum gripper armsmove toward each other away from anvils 306. Finally, oscillating drive371 is actuated to rotate vacuum gripper arms 364 back to the positionshown in FIG. 20 where, in the meantime, a new pair of end caps has beenmoved in position for delivery to the next end cap applying mechanism 48rotated into position on dial 46.

After the end cap applying mechanism has been provided with a pair ofend caps 24, assembly dial 46 is indexed to bring the next end capapplying mechanism into position for receiving its end caps. Eventually,each end cap applying mechanism 48 reaches magazine assembly station 52,where a prewound spool of film will be inserted into very open shell 28,the shell will be closed and end caps 24 will be applied. When each endcap applying mechanism 48 has reached assembly station 52, the radiallyouter ends of the mechanism come to rest between the inboard andoutboard skewer mechanisms illustrated in FIGS. 27 to 31, to bedescribed subsequently. In this position of end cap applying mechanism48, lips 20c,20t of very open shell 28 are oriented so that the shellopens essentially downwardly, as illustrated schematically in FIG. 4,thus permitting a prewound spool of film to be inserted from below.

WOUND SPOOL TRANSFER MECHANISM 56

When end cap applying mechanism 48 has come to rest, the wound spooltransfer mechanism 56 illustrated in FIGS, 22 to 26 is actuated toinsert a prewound spool into very open shell 28. Wound spool transfermechanism 56 comprises a circular frame base 410 which is attached tothe output hub of a conventional oscillator 412, through a hole 414 inface plate 32. As shown in FIG. 3, mechanism 56 is positioned to theleft of magazine assembly station 52 and above spool winding station 54.A frame plate 416 is attached to the outer end of frame base 410 andextends to the right as illustrated in FIGS. 22 and 23. A pair ofsupport tubes 418, 420 are rigidly attached to frame plate 416 andextend outward at an angle to frame base 410 as shown in FIG. 23. A pairof gusset plates 422, 424 complete the attachment of support tubes418,420 to frame plate 416, as shown in FIGS. 23 and 24. At their outerends, support tubes 418,420 are rigidly attached to a tubular housing426 within which a pair of linear bushings 428,430 slidably support aspline shaft 432. Attached to the lower end of shaft 432 is a mountingblock 434 having near its center as viewed in FIG. 24 a through bore 436in which a pair of bearings 438,440 rotatably support the shaft 442 of acam plate 444. As seen in FIGS. 24 to 26, cam plate 444 comprises alaterally extending arm 446 which is used to actuate the cam in a mannerto be described. Just beneath the center of rotation of cam plate 444,as viewed in FIGS. 24 and 26, a sinuous through slot 448 is providedwhich comprises an arc 450 of constant centerline radius from the centerof shaft 442, located close to the circumference of shaft 442; and anarc 452 of steadily increasing radius from the center of shaft 442. Asshown in FIG. 26, the centerline of arc 452, shown in phantom, isessentially straight following an initial transition from arc 450. Astatic cam follower roller 454 is positioned within slot 448 by means ofa downwardly depending static follower arm 456 which is attached to thelower end of tubular housing 426 by an integral mounting block 458. Dueto the configuration of slot 448, pulling upward on laterally extendingarm 446 will cause rotation of cam plate 444 in the counterclockwisedirection as viewed in FIGS. 24 and 26, thus causing static roller 454first to roll within arc 450 of constant centerline radius; so that,mounting block 434 remains stationary. However, as cam plate 444continues to rotate in response to upward force applied to arm 446,static roller 454 is encountered by the essentially straight portion ofarc 452 of steadily increasing radius; so that, without further rotationof cam plate 444, mounting block 434 and spline shaft 432 move upwarduntil static roller 454 nears the end of arc 452 when cam plate 444 hasreached the position shown in phantom in FIG. 24.

As seen in FIGS. 23 and 25, mounting block 434 is provided in its sidesurfaces with axial through slots 460,462 which extend from the bottomsurface to the upper surface of the mounting block. Within slots 460,462are pivotably mounted gripping fingers 464,466 by means of hinge pins468,470 located above the lower ends of the slots. As seen in FIG. 22,at their lower ends gripping fingers 464,466 are provided withessentially semicircular fixed jaws 472 sized to fit readily over thehubs 16 of a prewound spool 10 of film. The inner surfaces of the lowerends of gripping fingers 464,466 are provide with flat surfaces 474 tofrictionally engage flanges 14 of each spool, as shown in FIG. 24. Aboveflat surfaces 474, the gripping fingers are provided with reducedcrossections to make them somewhat resilient, thus minimizing the chancefor damaging a spool as the fingers close.

At their upper ends, gripping fingers 464,466 are provided with movablecam follower rollers 476,478 whose support axles extend, as shown inFIG. 25, through arcuate slots 480,482 in the side walls of slots460,462 to permit rollers 476,478 to engage arcuate slots 484,486 in camplate 444. Referring to FIG. 26, the center line radius of arcuate slot486 from the center of shaft 442 is somewhat longer at the upper end ofthe slot than at the lower; while for arcuate slot 484, it is the centerline radius at the lower end that is longer. Because of this change incenterline radius along slots 484,486, rotation of cam plate 444 in thecounter clockwise direction in the manner previously described willcause the upper ends of gripping fingers 464,466 to move toward oneanother, thereby causing the flat surfaces 474 at the lower ends of thegripping fingers to move apart and releasing any spool previously heldtherebetween. When movable rollers 476,478 near the ends of slots484,486 opposite to their positions in FIGS. 24 and 26, the shape ofslots 484,486 causes rollers 476,478 to dwell so that the grippingfingers do not swing outward into contact with the anvils. At about thesame time, static roller 454 enters the straight portion of slot 448; sothat, further upward movement of mounting block 434 occurs withoutrotation of cam plate 444. Then, when cam plate 444 is acted upon by aforce downward on laterally extending arm 446, mounting block 434 movesdownward while static roller 454 is in the straight portion of slot 448and stops when static roller 454 encounters the constant radius portion450 of slot 448, at which time cam plate 444 begins to rotate in theclockwise direction, causing the upper ends of gripping fingers 464,466to move outwardly and forcing flat surfaces 474 toward one another togrip a spool.

Cam plate 444 is rotated between the positions just described by themechanism shown in the upper portions of FIGS. 22 to 24. An actuatorshaft 488 extends through oscillating drive 412 from a conventionaloscillator, not illustrated, which can move the shaft parallel to itsaxis as indicated by the arrows. Within frame base 410, actuator shaft488 is operatively connected to a swivel bearing assembly 490 comprisinga pair of bearings 492 whose inner races are fixed relative to shaft 488and whose outer races are held within a bearing body 494. Opposite theend of shaft 488, a cap 496 is attached to bearing body 494 and providedwith a flange 498 pivotably connected to an actuator link 500 rigidlyattached to a drive shaft 502. A pair of bearing blocks 504,506 supportdrive shaft 502 and are attached to the front surface of frame plate416. Drive shaft 502 extends beyond gusset plate 422 as seen in FIG. 23and at its end is rigidly attached to one end of an intermediate link508 whose opposite end is pivotably attached to one end of a cam platelink 510 whose opposite end is pivotably attached to laterally extendingarm 446 of cam plate 444. Thus when actuator shaft 488 is moved to theleft as seen in FIG. 24, drive shaft 502 is rotated clockwise to raisecam plate link 510 to the position shown in phantom, thereby applying aforce essentially parallel to spline shaft 432, thus rotating cam plate444 and translating the assembly of mounting block 434 and cam plate 444in the manner previously described. Because of the presence of swivelbearing assembly 490, frame base 410, frame plate 416 and everythingattached to them may be rotated by oscillating drive 412 while actuatorshaft 488 is translating without rotation.

In operation of the mechanism shown in FIGS. 22 to 26, a prewound spool10 is prepared at spool winding station 54 and presented by means notshown to the position shown in FIG. 22. At this position, the free endof the film strip 12 is acquired by a vacuum foot 512 secured tomounting block 434 by a downwardly depending arm 514. Vacuum applied tofoot 512 by means not illustrated holds the free end of the film toprevent the film's unwinding during transfer to magazine assemblystation 52. Gripping fingers 464,466 are lowered simultaneously over thehubs of spool 10 and moved laterally into secure engagement with flanges14. Oscillating drive 412 is then actuated to rotate the assemblycounterclockwise, as viewed in FIG. 22, until the prewound spool hasbeen positioned within very open shell 28 held within end cap applyingmechanism 48 at magazine assembly station 52. In this position, grippingfingers 464,466 are located outside fixed claws 142,144, thereby leavingthe space between the fixed claws for insertion of the jaws of shellclosing mechanism 58, as will be discussed subsequently.

SPOOL SKEWER MECHANISMS

Then, the skewer mechanisms shown in FIGS. 27 to 31 are actuated toaccurately position the spool for closure of very open shell 28 andapplication of end caps 24. Just above magazine assembly station 52,face plate 32 supports a frame 516 for the skewer mechanisms provided toproperly position prewound spool 10 within very open shell 28. Frame 516comprises a base plate 518 attached to face plate 32 in front of anopening 520 through face plate 32. Attached to and extended outwardlyfrom base plate 518 are essentially inverted U-shaped side plates522,524, joined along their upper edges by top plate 526, along theirouter edges by end plates 528,530 and along their lower edges by bottomplates 532,534. Base plate 518 is provided with an opening 536 oppositeopening 520 in face plate 32. Supported on either side of opening 536 onthe back side of base plate 518 is the skewer actuating mechanism 538illustrated in detail in FIGS. 29 to 31. Mechanism 538 actuates aninboard skewer assembly 540 and an outboard skewer assembly 542. In thelatter case, a dog leg, or U-shaped, link 544 extends outward frommechanism 538, upward between side plates 522,524, across the gapdefined by the U-shaped side plates and downward through an opening, notillustrated, in bottom plate 534. After an end cap applying mechanism 48has been indexed into magazine assembly station 52, as illustratedfragmentarily in FIG. 27, wound spool transfer mechanism 56 swings aprewound spool into position between magnetic anvils 306 and inapproximate alignment with central bores 312 of the anvils. Mechanism538 is then actuated to cause inboard skewer assembly 540 to moveoutwardly a fixed distance and stop with its skewer probe 546 insertedthrough the end cap 24 held by anvil 306 and into the inboard hub of theprewound spool. Acting through dog leg link 544, mechanism 538 causesoutboard skewer assembly 542 to continue to move inwardly until itsskewer probe 548 is inserted through the other end cap 24 and into theoutboard hub of the prewound spool. To allow for some lateralmispositioning of the prewound spool, to compensate for variability inspool length and also to push the spool against the reference datumprovided by the dwelling inboard skewer, outboard skewer probe 548 isenabled to retract somewhat into the housing of skewer assembly 542.Probe 548 is slidably mounted in a bushing 550 and on the opposite sideof bushing 550 is provided with a piston 552 which moves in a bore 554provided in the housing. The side of piston 552 opposite to probe 548 isconstantly pressurized with air to provide a force to hold probe 548outward, the air being permitted to bleed by the piston and escapethrough a vent passage 556 through the wall of the housing. After theprewound spool has been properly positioned by probes 546,548, shellclosing mechanism 58, to be described subsequently, is actuated to closevery open shell 28 about the prewound spool. The free end of the filmstrip 12 thus is held between lips 20c,20t. Wound spool transfermechanism 56 then releases the spool and withdraws to pick up the nextspool. With shell closing mechanism 58 still gripping the closed shell,end cap applying mechanism 48 is then actuated in a manner to bedescribed subsequently, so that end caps 24 are applied to the closedshell. Shell closing mechanism 58 then withdraws, leaving the assembledmagazine held by anvils 306. Mechanism 538 then causes skewer assemblies540,542 to withdraw their probes from the assembled magazine, so thatassembly dial 46 can be indexed to end cap staking station 60.

FIG. 29 shows a top view, partially broken away, of actuating mechanism538; FIG. 30 shows a back view, partially broken away; and FIG. 31 showsa view taken along line 31--31 of FIG. 30. The housing for mechanism 538is attached to the back side of base plate 518 and comprises a top plate558 and a pair of rigidly attached depending side plates 560,562 betweenwhich inboard skewer mechanism 540 is mounted. The housing of mechanism540 is provided with an upwardly extending mounting flange 564. On theside of flange 564 facing side plate 562 are mounted a pair of slides566,568 which are slidably engaged with a rail 570 mounted on the sideof side plate 562 facing flange 564. Thus mechanism 540 can move backand forth on rail 570. As seen in FIGS. 29 and 31, flange 564 isprovided with a notch near its center to fixedly receive a cam block 572having a sinuous cam slot 574 formed in its side facing side plate 560.Slot 574 extends transverse to the desired direction of movement ofskewer assembly 540. To simultaneously move both cam block 572 and dogleg link 544, a double eccentric assembly 576 is mounted in side plate560. A crank bearing 578 is mounted in side plate 560 and rotatablysupports a crank 580 having on its outer end a drive pulley 582 and onits inner end an eccentric throw 584 which supports the inner race of abearing 586 on whose outer race is mounted the inboard end of dog leglink 544. Drive pulley 582 may be driven by a conventional indexer, notillustrated. To the inner end of throw 584 is fixedly mounted one end ofan oppositely eccentric throw or crank arm 588 at whose other end ismounted a cam follower roller 590 which rides in sinuous cam slot 574.Throw 584 and cam follower roller 590 are positioned 180 degrees apartrelative to the axis of rotation of crank 580. Thus, as crank 580 isrotated by means not illustrated, the end of dog leg link 544 mounted onbearing 586 and cam block 572 will oscillate back and forth in oppositedirections, causing skewer assemblies 540,542 to move into and out ofengagement with the spool held by end cap applying mechanism 48. So thatinboard skewer assembly 540 will cease movement before outboard skewerassembly 542 in the manner and for the purpose previously described,sinuous cam slot 574 is provided midway with a dwell segment 592 havinga radius of curvature equal to that of the path of travel of camfollower roller 590. This causes inboard skewer assembly 540 to movetoward the spool until segment 592 is encountered by cam follower roller590, at which time skewer assembly 540 ceases movement until segment 592is departed. While cam follower 590 is traversing segment 592 and skewerprobe 546 is stationary, throw 584 causes probe 548 to continue to moveinto the hub of the spool. When probe 548 is properly positioned,mechanism 538 dwells briefly while the magazine is assembled.

At the other end of dog leg link 544, as seen in FIGS. 27 and 28outboard skewer assembly 542 is mounted to the underside of bottom plate534 by means of a rail 596 mounted on bottom plate 534 and a pair ofslides 596,598 mounted on the housing of skewer assembly 542. The end ofdog leg link 544 is pivotably attached to the housing of skewer assembly542 by means such as a spherical bearing. To prevent dog leg link 544from tipping within frame 516, a pair of coaxial support posts 600,602are rigidly mounted to side plates 522,524 near the upper end of theportion of link 544 which extends downwardly to skewer assembly 542.Posts 600,602 rub against wear plates 604,606 attached to opposite sidesof link 544 and thus hold link 544 in an upright position during itsperiodic movements.

SHELL CLOSING MECHANISM 58

While the probes 546,548 of skewer assemblies 540,542 are properlypositioning the prewound spool for closure of the very open shell, shellclosing mechanism 58, illustrated in FIGS. 32 to 36, is rotating intoposition to close the shell. As shown in FIGS. 32 and 35, mechanism 58comprises an outwardly extending arm 608 having a base flange 610 whichis operatively connected to a conventional oscillator, not illustrated,mounted on the opposite side of face plate 32. The center of rotation ofbase flange 610 is indicated at 612. Offset from center 612, a stub axle614 is mounted to base flange 610. A roller bearing 616 is supported bystub axle 614 and a sleeve 618 is rotatably mounted on bearing 616. Atits end closer to base flange 610, sleeve 618 is provided with aradially extending arm 620, shown rotated into view in FIG. 35 for easeof illustration. Arm 620 is pivotably attached to one end 622 of aconnecting rod 624 whose other end 626 is pivotably attached to arotatable actuator arm 628 operatively connected to a conventionaloscillator, not illustrated, mounted on the opposite side of face plate32. Thus, movement of actuator arm 628 causes arm 620 to rotate sleeve618, for a purpose to be discussed. At its other end, sleeve 618 isfixedly attached to a timing belt pulley 630 which is shown in FIG. 35in a position corresponding to FIGS. 32 and 34. Arm 608 dog legsoutwardly from base flange 610 above the assembly of shaft 614, sleeve618 and timing pulley 630 and then radially above timing pulley 630. Atthe upper end 632 of its radial portion above timing pulley 630, arm 608is provided with an outwardly extending boss 634 having a through bore636 parallel to stub axle 614. Within bore 636, a shaft 638 is rotatablymounted on bearings 640. On the end 642 of shaft 638 above timing pulley630 is fixedly mounted a timing pulley 644 and a timing belt 646 isfitted around pulleys 630 and 644. Thus, rotation of timing pulley 630due to movement of actuator arm 628 causes shaft 638 to rotate. Tofacilitate adjustment of the tension in timing belt 646, the outercylindrical flange of timing pulley 630 is split axially at diametrallyopposed locations 630'; and timing belt 646 is cut and clamped at itsends 646' directly to the halves of the split flange. The halves of theflange each are provided with radially outwardly extending flanges 648between which a tension adjustment bolt 650 extends. By adjusting thecircumferential distance between the two flanges 648, the tension intiming belt 646 can be changed. Once the desired tension has beenachieved, the halves of the split flange are secured to the body of thepulley by means of bolts 652 which extend through circumferentiallyelongated slots in the halves of the split flange. Timing of therotation of the split flange relative to the rotation of radiallyextending arm 620 may adjusted by conventional means familiar to thoseskilled in the art, not illustrated.

On the end of shaft 638 opposite to timing pulley 644 is fixedly mountedthe actuator crank 654 of a linkage which is adapted to close very openshell 28 held within end cap applying mechanism 48, illustratedfragmentarily in FIGS. 32 to 34. The linkage is illustrated in largerscale in FIG. 36. A ground member 656 is attached to the underside ofboss 634 and extends laterally beneath crank 654. Pivotably attached tothe underside of ground member 656 is a first rocker link 658 and asecond rocker link 660. The outer end of crank 654 is pivotably attachedto one end of a link 662 whose other end is pivotably attached to acoupler link 664. A pair of attachment flanges 666, only one of which isvisible in FIG. 36, extend on either side of a central slot 668 incoupler link 664, shown in phantom, slot 668 being sized to allow thepassage of rocker links 658,660 which are pivotably attached to couplerlink 654 between flanges 666. As seen in phantom in FIG. 36, rocker link660 extends past its pivot to flanges 666 and includes at its outer endan essentially semicylindrical jaw portion 670 having an axial lengthsomewhat less than the spacing between fixed claws 142,144 of shellremoval mechanism 44; so that, jaw portion 670 can pass between fixedclaws 142,144 during closure of very open shell 28. Jaw portion 670 isprovided with an inner semicylindrical geometry which extends on bothsides of slot 668 and is essentially congruent with that desired for thefinished magazine over approximately 180 degrees measured from lip 20cof the very open shell and from an axially extending tip edge 672 forengaging lip 20c. Jaw portion 670 is also provided with a heel portion674 which extends beyond its cylindrical portion and extends within slot668 when the mechanism is closed as seen in FIG. 36. Heel portion 674provides support for the very open shell during closure, thus preventingthe formation of a bulge as the shell is closed. See also FIG. 33 wherethe closure mechanism is open. Beyond slot 668 and opposite jaw portion670, coupler link 664 is provided with an essentially cylindrical jawportion 676 with an inner cylindrical geometry which extends on bothsides of slot 668 and is essentially congruent with the geometry desiredfor the finished magazine cover over somewhat less than 180 degrees, toallow for clearance for lips 20c, 20t.

The cycle of operation of shell closing mechanism 58 commences from theposition shown in FIG. 32. Actuator arm 628 has been rotatedcounterclockwise to lift end 622 upwardly, thus rotating timing pulleys630,644 and causing actuator crank 654 to pull jaw portions 670,676apart. In the illustrated embodiment, pulley 644 must turn about ninetydegrees to fully open jaws 670,676; but pulley 630 turns less since itis somewhat larger in diameter. In the position of FIG. 32, the centerof the pivot connecting end 622 to arm 620 coincides with center ofrotation 612 of arm 608, thus preventing inadvertent rotation ofactuator crank 654 when arm 608 rotates about center 612. As end capapplying mechanism 48 moves into magazine assembly station 52, arm 608is rotated in synchronism, so that it reaches the position shown in FIG.33 just as mechanism 48 comes to a stop. To reach this position,separated jaw portions 670,676 pass between fixed claws 142,144 and oververy open shell 28 where it is held by fixed claws 142,144. Actuator arm628 is then rotated clockwise to force end 622 downwardly to theposition of FIG. 34, thus rotating timing pulleys 630,634 and causingactuator crank 654 to force jaw portions 670,676 together. As the jawportions move together, they engage very open shell 28 with essentiallyno relative rotation, thus minimizing any scratching of the surface ofthe completed magazine. The jaws close the shell to a good cylindricalshape and remain closed until end caps 24 have been installed. After thejaws have closed, the wound spool transfer mechanism 56 releases thehubs of the spool and the tail end of the film and withdraws to pick upthe next spool, as previously described.

The mechanism for actuating end cap applying mechanism 48 is illustratedin FIG. 5. A stand off hub 678 is attached to the outer end of centralstationary support tube 68 and supports a pair of bearings 680surrounding the end of actuator shaft 80. A bevel gear 682 is attachedto the end of shaft 80 and meshed with a further pair of angularlyspaced bevel gears 684,686 rotatably supported by stand off hub 678 inbearings 688. Bevel gears 684,686 are fixedly attached to stub shafts690,692 which carry at their outer ends plates 694,696 having diametralslots 698. Plates 694,696 are positioned relative to magazine assemblystation 52 and magazine removal station 62, respectively, so that whenend cap applying mechanism 48 is indexed into such stations, both slots698 are entered by a cam follower roller 700, carried by a cam followerarm 702 affixed to the end of crank shaft 216 as shown in FIGS. 11, 12and 14. Thus, when actuator shaft 80 is rotated by a conventionaloscillator, not illustrated, plates 694,696 cause crank shaft 216 torotate to close the anvils 306 and apply end caps 24 at magazineassembly station 52, and simultaneously to open the anvils 306 torelease a completed magazine at magazine removal station 62.

After end cap applying mechanism 48 has been actuated to apply end caps24 to the closed shell held by cylindrical jaw portions 670,676,actuator arm 628 is rotated counterclockwise to lift end 662 upwardly,thus rotating timing pulleys 630,644 clockwise and causing actuatorcrank 654 to pull jaw portions 670,676 apart. Due to the configurationof the linkage shown in FIG. 36, jaw portions 670,676 do not contact theclosed shell as the jaws open. Simultaneously, skewer assemblies 540,542are withdrawn in the manner previously described. Finally, arm 608 isrotated back to the position of FIG. 32 to permit assembly dial 46 toindex the just assembled magazine to end cap staking station 60.

Though our invention has been described with regard to a singlecylindrical shell, those skilled in the art will understand from thedisclosure that the mechanisms of the assembly dial are capable, incooperation with the end cap feeding mechanism, the skewer mechanisms,the wound spool transfer mechanism and the very open shell closingmechanism, of sequentially applying caps to a plurality of such shells,with various magazines being in different states of completion at anyone time. The synchronization of the various indexers and oscillatorsdisclosed for operating the dials and other mechanisms to achieve suchoperation is well within the skill of those in the mechanical arts.

While our invention has been shown and described with reference toparticular embodiments thereof, those skilled in the art will understandthat various modifications in form and detail of the apparatus andmethod may be made without departing from the scope and spirit of theinvention.

Having thus described our invention in sufficient detail to enable thoseskilled in the art to make and use it, we claim as new and desire tosecure Letters Patent for:
 1. A method of applying end caps to asubstantially cylindrical shell having substantially circular end edges,comprising the steps of:providing a pair of relatively movable jaws;providing on each of said jaws means for holding one of such end caps;placing one of such end caps in each of said means for holding;positioning such a shell between said jaws; and closing said jaws toapply such end caps to such end edges.
 2. Apparatus for applying endcaps to a substantially cylindrical shell having substantially circularend edges, comprising:a support; at least one pair of relatively movablejaws mounted on said support; means located on each of said jaws forholding one of such end caps; means located between said jaws forpositioning one of such shells to receive such end caps; meanspositioned adjacent said support for placing an end cap in each of saidmeans for holding; and means for closing said movable jaws to apply saidend caps to such circular end edges.
 3. Apparatus according to claim 2,wherein said movable jaws comprise:a pair of elongated frame members;means extending between said frame members for constraining said jaws toparallel movement toward and away from each other; and wherein saidmeans for closing said jaws comprises: a frame attached to said support;a rotatable crank shaft mounted in said frame and connected to saidframe members by oppositely movable connecting rods; and means forrotating said crank to close and open said jaws.
 4. Apparatus accordingto claim 2, wherein said end caps are made from magnetic material andsaid means for holding one of said end caps comprises a pair of magneticmembers, one mounted on each of said jaws.
 5. Apparatus according toclaim 2, wherein said means for placing an end cap comprises:a pair ofcap delivery wheels rotatably mounted adjacent to said support, each ofsaid wheels comprising peripheral pockets for carrying said caps; meansfor feeding caps into said pockets on each of said wheels; means forsequentially removing a pair of said caps from said wheels andtransferring said caps to said means for holding.
 6. Apparatus accordingto claim 5, wherein said means for sequentially removing comprises;asecond frame mounted for rotation adjacent to said support; a pair ofcap transfer arms pivotably mounted to said second frame, each captransfer arm having an outer end selectively positionable upon rotationof said second frame into proximity either with one of said peripheralpockets or with one of said means for holding; means for selectivelypivoting said cap transfer arms toward or away from said peripheralpockets, or toward or away from said means for holding; means at saidouter end of each said cap transfer arm for securing a cap to said outerend; and means for rotating said frame to position said transfer armsalternately in proximity with said peripheral pockets and with saidmeans for holding.